Kokam Battery Technology For Navy/Military Aircraft

Battery Requirements for

Application of Lithium Ion and Lithium Polymer

ToAchieve Standardizationand Improved Reliability

Bill JohnsonManager AIR-4.4.5.2 Electrical PowerE-mail: william.r.johnson@navy.mil

Phone: 301-342-0810

Agenda

Aircraft Battery Functions

Present Batteries

Present Reliability

Battery Technology Development Underway

Specification Requirements –

Direct Current Buss Charging–

Safety–

Service life and logistics

Cost of Ownership–

Present Battery Costs–

Lithium Battery Costs

Technology Development to Address These Costs

Standardization Opportunity that Could Address Costs

Planned Demonstrations

Aircraft Battery Functions

DC

BUS

EngineEngine

GeneratorGenerator

Power Supply

External ElectricalExternal ElectricalPowerPower

EPMEPM

User User EquipmentEquipment

Stores Stores ManagementManagement

Utility Utility EquipmentEquipment

BatteryBattery

ConverterConverter

ElectricElectricStarterStarter

AC

BUS

InverterInverter

BatteryBatteryChargerCharger

APUAPU GeneratorGenerator

�� Green Green -- Propulsion & PowerPropulsion & Power�� Blue Blue –– Electrical System Electrical System

ComponentComponent

APU Start

Charge From DC Bus

DirectEngineStart

Present Navy Battery Applications & Chemistries

Presently there are 22 Navy aviation platforms

Sealed Lead-Acid batteries are presently used on 15 platforms–

Advantages•

No scheduled Maintenance for 2-3 years of service life•

Floats on DC Bus–

Disadvantages•

Higher weight than other chemistries•

Requires heater blankets at cold temperature to assure proper charge•

Environmental concerns

Nickel-Cadmium batteries used on 7 platforms–

Advantages•

Higher energy density than Lead-Acid•

Lighter weight–

Disadvantages•

Requires periodic maintenance•

Environmental concerns

Present Reliability

Aircraft System Mean Flight Hours Between Failures

MMH/K Flight Hours

MH-53E Sealed Lead-AcidD8565/1-2

65834 43.2

CH-53E Sealed Lead-AcidD8565/1-2

5607.1 24.6

F/A-18D Sealed Lead Acid D8565/4-1

3117.6 26.7

F/A-18F Sealed Lead Acid D8565/14-1

635.0 171

AH-1W Nickel-CadmiumM8565/10-1

182.2 159.9

UH-1N Nickel-CadmiumM81757/16-1

401 97.3

Data Represents Period from 7/08 to 12/08

MIL-PRF-29595A Lithium

MIL-PRF-29595A LithiumRechargeable Battery

Specification Cover Page

Additional specification requirements for Lithium–

Direct Current Buss Charging (2 Hour Charge)

•

Electronics–

Shunts current around fully charged cells–

Cell Balancing–

Control inrush current

–

Service Life and Logistics•

Electronics–

Prevent complete rundown of battery–

BIT display–

Life Cycle Requirements –

600 cycles 100% DoD

with 28.25 CP charge for 2 hours

•

100 cycle (-18°C / 0°F)•

100 cycles (43°C / 110°

F)•

100 cycles (24°

C / 75°

F)•

Repeat previous 3 steps

MIL-PRF-29595A Lithium (cont)

–

Safety•

Electronics–

EMI–

Inhibits charge at cold temperature or heater blankets–

Prevent overcharge of cells–

Prevents under-discharge•

Additional Safety Tests–

S9310-AQ-SAF-010 Technical Manual Requirements•

Short Circuit Test•

Overcharge/Discharge Test•

Over-discharge/Charge Test•

High temperature Test•

Electrical Safety Device Test•

Aging Safety Test–

Discharge at maximum operational temperature

MIL-PRF-29595A Lithium (cont)

Intelligent Battery Charger–

Eagle Picher•

Automated charger setup by part number•

Return sulfated batteries to RFI–

GEM Power •

Working to develop “universal”

intelligent battery charger•

Charger will determine battery chemistry (i.e., Lead-acid, Ni-Cd, Li-

ion), state of charge and select correct charging algorithm

•

Unit to include battery diagnostics/prognostics capability

STTR–

Topic N07-T002 –

“Aircraft Battery Diagnostic and Prognostic System”

–

Entered Phase II with contract award to GEM Power in November 2008

–

Goal is to develop passive battery diagnostic and prognostic capability to be incorporated into the aircraft health management system

Technology Development

Battery Developments–

Lithium Polymer –

Kokam

America•

F/A-18C/D (present battery 24 Volt, 7.5 Ah, 332 in cu., 26 lbs)–

24 Volts–

25 Ah–

332 in. cu., 13 lbs–

3 string of 7 cells•

AH-1W (present battery is 24 Volt, 35 Ah 1026 in. cu., 85 lbs)–

24 Volts–

50-60 Ah–

1026 cu. In., 55 lbs–

2 strings of 7 cells–

Lithium-ion –

SAFT •

N-UCAS–

24 Volts–

55 Ah–

GlobalHawk

design -

14 cylindrical cells –

2 strings of 7 cells (1115 cu. in., 49 lbs)

–

N-UCAS design –

7 prismatic cells in series–

662 cu. In., 43 lbs

Technology Development (cont)

F/A-18 Battery

Present D8565/4-1 SLAB Kokam

Proposed Lithium Polymer Design

Test Sample 1 2 3 4 1. Dimensions All The batteries mounting holes were not in complains. See note 1. 2. Strength of Vent Tubes

All

OK

OK

OK

OK

3. Color & Marking

All

No marking labels were on the batteries. See note 2.

4. Weight

All

16.65 lbs

15.85 lbs

15.7 lbs

lbs

5. Initial Capacity Discharge

All

0:53:51 22.45ah

1:09:25 28.94 Ah

1:07:45 28.30 Ah

1:08:16 28.45 Ah

6. Capacity Discharge

All

1:09:07 28.82ah

1:09:23 28.92 Ah

1:04:40 26.96 Ah

1:08:09 28.40 Ah

7. Emergency Loads @ Ambient

2

N/A

1:10:44 28.58ah

N/A

N/A

8. Emergency Loads @ -20F

2

N/A

1:05:56 26.36ah

N/A

N/A

9. Emergency Loads @ 0F

3

N/A

N/A

1:07:26 26.96ah

N/A

10. Emergency Loads @ 23F

2

N/A

1:08:00 27.19Ah

N/A

N/A

11. Emergency Loads @ 131F

1

1:11:24 29.44Ah

N/A

N/A

N/A

12. Start-up Loads @ 131F

3

N/A

N/A

3/9/2009

N/A

13. Start-up Loads @ -20F

2

N/A

3/11/2009

N/A

N/A

14. Start-up Loads @ Ambient

2

N/A

1.08Ah

N/A

N/A

15. Half-Hour Charge @ 0F

2

N/A

3/13/2009

N/A

N/A

16. Half-Hour Charge @ 59F

3

N/A

N/A

1:04:42 26.97Ah

N/A

17. Half-Hour Charge @ 131F

2

N/A

3/16/2009

N/A

N/A

18. Hour Charge @ -40F

2

N/A

1:03:56 26.65Ah

N/A

N/A

19. Life Cycling (600 cycles)

4

N/A

N/A

N/A

in progress

20. Hour Discharge @ 120F

2

N/A

3/18/2009

N/A

N/A

21. Discharge while Inverted (62.5 amps for 5 min)

2

N/A

5.2Ah

N/A

N/A

22. Altitude (60,000 ft)

3

N/A

N/A

3/3/2009

N/A

23. Mechanical Shock

3

N/A

N/A

N/A

24. Temperature Shock (160°F, -70°F)

2

see note 2.

N/A

N/A

N/A

25. Temperature Rise & Float

2

N/A

OK 1:13:55 30.83Ah

N/A

N/A

26. Vibration (62.5 amps for 3 min)

2

N/A

OK 3.12Ah

N/A

N/A

27. Humidity (10 days)

3

N/A

N/A

see note 2.

N/A

28. Salt Fog (2 days)

3

N/A

N/A

OK 25.15V

N/A

29. Ground Storage @ 122F (30 days)

3

N/A

N/A

N/A

30. Shelf Life (18 months)

4

N/A

N/A

N/A

31. Deep Discharge Recovery (122F for 7 days)

2

N/A

see note 5.

N/A

N/A

32. Physical Integrity @ 185F

1

1:01:22 25.59Ah

N/A

N/A

N/A

33. Final Examination

All

AH-1W Lithium Battery

External and Internal Views of AH-1W Lithium Polymer Batteries for the AH-1W by Kokam

GlobalHawk & N-UCAS Battery

GlobalHawk

Battery N-UCAS Battery

Cost of Ownership

Present Battery Cost–

Valve Regulated Lead Acid

•

Cost from $800 (F/A-18) to $2500•

Service Life of 2-3 Years

•

No scheduled maintenance–

Low Maintenance Nickel-Cadmium

•

Cost from $1200 to $7600 (AH-1W)•

Five year service life

•

One year maintenance cycle

Lithium Batteries–

Present Lithium Aircraft Batteries

•

B-2 -

$57K•

JSF –

Projected cost $100-150K (270V & 28V)

–

Projected Navy Lithium Battery Cost•

Kokam

America

–

AH-1W -

$7600–

F/A-18 -

$2500

•

SAFT–

N-UCAS Flight Certification Units -

$25K

Cost of Ownership (cont)

Technology Development to Address Cost Issues

SBIR Topic N08-017 Thermally Stable Lithium Batteries–

Increased temperature operating range•

To 71º

C Operating•

To 85º

C Exposure–

Resulting in:•

Increased service life•

Increased storage life (Logistics)•

Improved safety–

Phase I Option awarded in April ’09 to Yardney

Technical Products

STTR Topic N07-T002 Aircraft Battery Diagnostic and Prognostic System–

Phase II awarded Nov. 2008–

Diagnostics and prognostics•

Goal to incorporate hardware/software into aircraft–

Maintenance Computer–

Benefit•

Improved safety•

Removal at end of service life (instead of arbitrarily scheduled

service life)

Technology Development to Address Cost Issues (cont)

STTR Topic N04-029 - Prognostic Health Management of Primary 28V & Secondary 270V JSH Lithium (Li)-ion batteries–

Phase II awarded October 2008 to Global Technology Connection

–

Goal is to develop Prognostic Health Management (PHM) for both Lithium batteries used on the JSF

–

Technical approach is to develop battery life models for each battery

Battery Developments–

Kokam

America

•

Nano-technology for Lithium Polymer–

Quick recharge–

Reduced need for certain electronics–

Improved power capability–

Extend shelf and service life–

Improved safety–

SAFT America

•

N-UCAS Development–

Improved operational temperature range–

Lower Self-discharge•

Longer shelf life –

Improved electronics–

Stacked prismatic design

Technology Development to Address Cost Issues (cont)

Planned Demonstrations

AH-1W Lithium Polymer Battery (Kokam

America)–

FY09 –

Qualification Testing at NSWC Crane–

FY10 –

Safety Testing at NSWC Crane–

Late FY10 –

Flight Testing at NAS Pax

River

F/A-18 Lithium Polymer Battery (Kokam

America)–

FY09 –

Qualification Testing at NSWC Crane–

FY10 –

Safety Testing at NSWC Crane–

Late FY10 –

Flight Testing at NAS Pax

River

STTR Topic N07-T002 Aircraft Battery Diagnostic and Prognostic System–

Phase II –

Demonstration/Evaluation of prototype unit•

Prototype box for evaluation –

Late FY09•

Testing at Boeing’s FIRST Lab –

Early FY10–

Phase III –

Integration of system into aircraft (Onboard) –

Late FY10

Standardization Opportunities To Address Cost

Battery System Width (in) Depth (in) Height (in) Capacity (Ah)

D8565/17-1 SLAB 4.5 5.3 2.5 1/3

8565/1-2 SLAB 3.9 8.5 3.7 1.5

8565/6-1 SLAB 6.8 6.3 3.3 1.5

81757/14-1 Ni-Cad 4.5 11.2 4.7 5.5

8565/4-1 SLAB 6.7 11.5 5.7 7.5

8565/11-1 SLAB 9.8 8.4 7.8 10

8565/18-1 SLAB 12.1 5.7 5.5 10

8565/14-1 SLAB 7.1 13.9 6.6 15

8565/9-1 SLAB 10.0 10.7 8.9 24

8565/7-2 SLAB 11.6 11.7 9.1 24

81757/15-181757/15-3

Ni-Cad 10.010.0

10.710.7

8.98.9

2525

8565/5-18565/5-2

SLAB 12.2 11.8 10.4 30

81757/16-1 Ni-Cad 11.9 10.5 10.4 35

D8565/15-1 SLAB 10.0 10.7 8.9 35

8565/10-1 Ni-Cad 9.7 13.8 7.6 35

81757/18-1 Ni-Cad 6.5 11.0 10.3 55

29595/TBD Li-ion 7.7 9.9 8.8 55

Lithium Battery 1

Lithium Battery 2

Lithium Battery 3

Lithium Battery 4 –

High RateKokam

Battery Development 2

Kokam

BatteryDevelopment 1

Li Battery 5SAFT NUCAS

New Opportunities for Safety

NAVAIR 4.4.5 has submitted 2 new SBIR topics that are undergoing review for pre-

release for solicitations in 27 July 2009–

Non-Flammable Electrolyte for Lithium-ion batteries

–

Fire Suppression Systems for Lithium-ion Batteries

*www.acq.osd.mil/sadbu/sbir/solicitations

Questions?